Manufacture of High Precision Spur Gears With End Milling Cutters

1988 ◽  
Vol 110 (4) ◽  
pp. 359-366 ◽  
Author(s):  
S. G. Papaioannou
Keyword(s):  
Design Process ◽  
High Precision ◽  
End Milling ◽  
Spur Gears ◽  
Interpolation Algorithm ◽  
Simple Geometry ◽  
Milling Machines ◽  
Nc Milling ◽  
Center Path ◽  
Gear Profile

A new method is proposed for cutting large module spur gears on NC milling machines, using end milling cutters. End milling eliminates undercutting and leads to a significant reduction of tooling costs. The method relies on the motion of a simple geometry tool rather than the shape of an expensive form tool to generate the gear profile. The tool center path is defined and computed for the standard 20 deg full-depth system. Tool steps are generated by a highly precise interpolation algorithm. The practical aspects of the method are also investigated to establish its feasibility. The computation of the maximum tool size shows that sufficient tool rigidity can be secured for gear modules greater than or equal to 10 mm. The Lewis equation is used to investigate the beam strength of the resulting tooth profile and generate data for the design process. Gears made by end milling are shown to be comparable in strength to those produced by shaping or hobbing.

Study of the Effects of Miniaturization on Static and Dynamic Form Errors in Desktop Milling Machines

2009 ◽  
Author(s):  
Milad Vazirian ◽  
Mohammad-Reza Movahhedy ◽  
Javad Akbari
Keyword(s):  
Machine Tools ◽  
End Milling ◽  
Small Scale ◽  
Milling Machine ◽  
Fluid Consumption ◽  
Static Deflection ◽  
Surface Error ◽  
Form Errors ◽  
Dynamic Form ◽  
Milling Machines

Desktop and miniaturized machine tools are a new trend in small scale and customized manufacturing. The performance of these machines in terms of their energy consumption, machining fluid consumption and their precision have been investigated in the literature, but the effect of miniaturization on static deflection, stability against chatter and the resulting surface error has not been studied. In this paper, the performance of the desktop milling machine tool in terms of their static and dynamic form errors is studied. The performance of a miniature milling machine used for end milling of a typical workpiece is compared with a similar machine of conventional size through dimensional analysis and numerical modeling. The error of the surface finish generated is predicted and verified through simulation.

A Novel Method of Obtaining Honing Tool Profile for Machining Gears With Profile Modifications

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Michał Batsch
Keyword(s):  
Mathematical Model ◽  
Design Process ◽  
High Precision ◽  
Prediction Error ◽  
Industrial Applications ◽  
Helical Gears ◽  
Profile Deviation ◽  
Tool Profile ◽  
Novel Method ◽  
Two Parameter

Abstract In this study, a mathematical model of the honing process for helical gears with external teeth was developed. The proposed novel method of obtaining the two-parameter envelope of a family of surfaces proved useful in simulated machining by means of a tool with a profile deviation. Based on performed simulations and industrial applications, it was found that this method can be useful in predicting the accuracy of machined gear and therefore can be used in the design process of honing tool for high precision aerospace gears. For the example provided, the average absolute prediction error of machined tooth profile was 0.28 µm.

Joint optimization of product tolerance design, process plan, and production plan in high-precision multi-product assembly

2020 ◽  
Vol 54 ◽  
pp. 336-347 ◽  
Author(s):  
Daisuke Tsutsumi ◽  
Dávid Gyulai ◽  
András Kovács ◽  
Bence Tipary ◽  
Yumiko Ueno ◽  
...  
Keyword(s):  
Design Process ◽  
High Precision ◽  
Joint Optimization ◽  
Tolerance Design ◽  
Production Plan ◽  
Process Plan ◽  
Product Assembly

Contribution on the Optimization of the Spur Gears Design Process Using Software Application

2014 ◽  
Vol 658 ◽  
pp. 117-122
Author(s):  
Gheorghe Plesu ◽  
Stelian Cazan
Keyword(s):  
Programming Language ◽  
Design Process ◽  
Optimization Process ◽  
Spur Gears ◽  
Operational Method ◽  
Mathematical Functions ◽  
Standard Methods ◽  
Software Application ◽  
Gear Design ◽  
Design Steps

This paper illustrates a method, in conformity with Standards [10 - 14], regarding gear design. The optimization process using this method consists in reducing the number of design steps and also in its accuracy. This method takes into consideration the functionality of gears. This method, called also the operational method [1], involves 10 kinematic and dynamic restrictions, that provide a direct calculus of gears, without any iterations. The standard methods require successive iterations, until the appropriate result is obtained. The comparison between these methods is presented below. The kinematic and dynamic restrictions, being defined as mathematical functions, could easily be implemented in a programming language.

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